Shaping the world of blow moulding technology

Blow moulding has always been characterised by technological advances and dynamic market trends. For decades, the packaging sector has been influencing numerous plastics applications, with the expectation that the blow moulder can find the solutions.  

The centrepiece of Bekum’s interpack 2014 exhibit was the fully-electric EBLOW machine generation. The electric drive concept is very popular with manufacturers of plastic packaging due to its efficiency.  In addition to the clear benefits of the machine technology, extrusion blow moulding also meets the current trends in the packaging sector.  These include greater demands on design, extended service life, as well as rising demands for turnkey systems and resource conservation as part of the expanding sustainability goals of manufacturers.  

Plastic packaging and containers can be economically produced on the single- and double-station blow moulding machines of the electric EBLOW and hydraulic HYBLOW series from Bekum.  Bottles and containers with capacities of between 3 ml and 20 litres can be manufactured, depending on the machine type.  This makes an output rate of more than 100 million containers possible per year, depending on the size.  Modern production technologies, such as the “tandem blow” method, which enables simultaneous blowing from top and bottom from one extruding parison, are ideal for producing packaging of up to 330ml at very high volumes, such as for drinkable yoghurt and Actimel? bottles. The “tandem blow” method not only enables 100% higher output compared with conventional production processes,  it can also reduce the weight of the bottles by optimising the production of the system technology from Berlin.  This results in substantial savings on material compared to the usual standard market weights.  This is an impressive contribution toward conserving resources and improving sustainable production of hollow packaging.  

The extrusion low moulding method is proving increasingly popular with packaging processors due to its “geometricproduct versatility”, compared with stretch-blown products, for example. This design is beneficial in the retail pharmacy or food sectors as an option for getting certain packaging models onto the shelf very quickly. "Blow moulding also offers a degree of freedom or versatility for when packaging needs to be presented attractively on the shelf to promote sales" states Andreas Kandt, CEO of Bekum.

Extra protection assured

Packaging with built-in protective barriers, which are intended to prevent diffusion from the outside to the inside or vice-versa, can be produced with coextrusion technology. Food or pharmaceutical products need to be protected from oxidative reactions as much as possible.  This means that the higher the quality of the packaging equipped with barrier technology, the longer the shelf life will be.  A long shelf life (use by date) is a good selling point for consumers, as it facilitates stocking and tends to reduce the waste rates for food in retail and for the end users.   With Bekum, this logic can be applied to food or retail pharmacy packaging, but especially to pharmaceutical packaging.  “If valuable contents need to be protected, coextrusion blow moulding technology offers many options, which ‘traditional’ packaging is not able to provide”, adds Mr. Kandt.

The spiral distributor extrusion heads from Bekum are especially suited to coextrusion technology.  They provide an excellent, even parison wall thickness distribution, which opens up significant potential for the processor for optimising the parison quality and the neck finish. 

The combination of great precision and high structural rigidity in the EBLOW series ensures improved product quality and process reliability, as well as energy and material efficiency.  This results in a whole host of relevant benefits in terms of efficiency in everyday processing production.  Thus, the high precision of the calibration, coupled with the effective support of the mould carrier in the C-frame, ensure that the quality of the mould parting line is consistently high, especially in the critical neck area, even after many hours of operation.  The machine is highly resistant to wear: the service life is significantly increased by the balanced, even load.

Shaping the blow moulding world

Since 1959, Bekum has shaped the world of blow moulding technology like no other company. Numerous developments are closely linked to its founder, Gottfried Mehnert.  “The task of being a technological pioneer is challenging. When it comes to excellence in terms of output quantity and high quality, everyone knows us.  However, there are many other competitors out there offering attractive solutions that represent good value for the money.  For us, this means we need to focus on the areas in which we are particularly strong: providing the best service and quality available on the worldwide market,” according to Mr. Kandt.

Bekum's annual sales volume at the moment is around €80 million, with 370 employees.  Within 24 months, the company hopes to raise it to €100 million. To this end, the company has set a variety of goals across all areas of the business.  They cover a number measures aimed at improving its processes, optimising its purchasing, making project management more efficient and coordinating better between subsidiaries in the USA and Brazil, and European plants in Berlin and Traismauer.   

Current, a two-fold approach to putting Bekum's already strong relationships with its customers on a new footing is being implemented.  “Up until now, we have been recognised as machine suppliers.  Cooperative efforts with selected partner companies are no longer an issue when seen in the context of forging ahead with our project business. Today, our high-performance machinery operates in a largely automated environment with constantly changing market demands. For our worldwide customers, not only our own contribution to the system, but also the entire concept has to be correct,” according to Mr. Kandt.

Bekum is well on its way to more innovations. Mr. Kandt says: “Well, you know I can't really go into too much detail! We are currently working on the technology to expand platforms.  The electric blow moulding machine will be a definite, considerable focus.  Here, we will expand our leadership role with regard to technology and market presence. No one has such a persuasive electrical drive technology concept as we do.  We will continue grow and strengthen in this area.  We will also reorganise our staffing. At the turn of the year, a new technical director joined us.  His responsibilities are to increase our portfolio, integrate system partners, and further develop control and sensor technology.”

The focus of the new technical management at Bekum is rheology, extrusion technology, and head technology.  In agreement with the Service Department, Bekum will be focusing on the area of retrofitting.  Hardly any other used machines in the plastic industry are as sought after as those from Bekum.  Even after 25 years of service, the purchase of a second-hand machine is still a good investment.  Companies in emerging markets start out with a used Bekum blow moulding machine and then, when they have made enough money, move on to a new Bekum. It fits in very well with the company’s long-term marketing strategies